Structural reinforcements

ABSTRACT

A structural reinforcement for an article including a carrier ( 10 ) that includes: (i) a mass of polymeric material ( 12 ) having an outer surface; and (ii) at least one fibrous composite insert ( 14 ) or overlay ( 960 ) having an outer surface and including at least one elongated fiber arrangement (e.g., having a plurality of ordered fibers). The fibrous insert ( 14 ) or overlay ( 960 ) is envisioned to adjoin the mass of the polymeric material in a predetermined location for carrying a predetermined load that is subjected upon the predetermined location (thereby effectively providing localized reinforcement to that predetermined location). The fibrous insert ( 14 ) or overlay ( 960 ) and the mass of polymeric material ( 12 ) are of compatible materials, structures or both, for allowing the fibrous insert or overlay to be at least partially joined to the mass of the polymeric material. Disposed upon at least a portion of the carrier ( 10 ) may be a mass of activatable material ( 126 ). The fibrous insert ( 14 ) or overlay ( 960 ) may include a polymeric matrix.

TECHNICAL FIELD

The present invention relates generally to composite materials,particularly to composites having a thermoset matrix phase, which can beemployed in a number of applications, such as for use in transportationvehicles, building materials, sporting equipment or other rigid,lightweight articles.

BACKGROUND

There is an ongoing effort in many industries to lighten the weight ofarticles. In many instances, this is achieved by the selection ofmaterials that have a lower density, thinner section thicknesses orboth, as compared with prior materials or structures. As a result, thereis a potential for the weakening of structures, and the consequent needfor stiffening or other structural reinforcement.

In the field of automotive vehicle manufacturing it is common to employstructural reinforcements within cavities of the vehicle body structure.For instance, it has become common to employ within a cavity of thevehicle body structure a relatively rigid molded polymeric carrier thatcarries an activatable material on one or more of its outer surfaces.For certain activatable materials, upon being activated (e.g., by theheat from a coating bake oven), the activatable material can expand andbond to a surface defining the cavity.

In order to selectively control the properties of the articlereinforcement structure, it has been taught to use hybrid reinforcementstructures that include a combination of multiple materials for thecarrier. See, e.g., U.S. Pat. No. 8,430,448, hereby expresslyincorporated by reference for all purposes. See also, Patent CooperationTreaty (PCT) Application No. WO 2010/054194, hereby expresslyincorporated by reference for all purposes.

In the automotive vehicle industry, the use of computer modeling (e.g.,finite element analysis) has been employed for simulating a vehiclecrash, and for modeling how a particular section of a vehicle willrespond to the crash. Such modeling can be utilized to determineappropriate locations for the placement of reinforcing structures.

Notwithstanding the above efforts there remains a need for alternativecarrier structures. For example, there remains a need for alternativecarrier structures that employ a combination of different materialsthat, even though they are dissimilar, are still generally compatible(e.g., chemically and/or physically compatible) with each other so thatthey can be joined together without the need for an adhesive, amechanical fastener, or other means for physically joining two or moredifferent materials. There also remains an ongoing need for alternativecarrier structures that employ a combination of different materials thateach contains a substantial polymeric portion (e.g., a non-metallicportion) so that weight savings can be attained. There is also a needfor polymeric materials that can be combined to increase the overallmodulus and flexural strength of a reinforcement, such that it exceedsthat of any of the materials on their own. There also remains an ongoingneed for alternative carrier structures that employ a combination ofdifferent materials that join together at an interface region that isgenerally continuous with the portions of the carrier defined by thedifferent respective materials. There also remains an ongoing need foran alternative carrier that can employ one or more localizedreinforcement regions by use of a particular material within thecarrier, and which may be achieved in the absence of a need for astructural feature (e.g., a rib) for imparting additional strength tothe localized reinforcement.

Examples of composite structures are illustrated in PCT Publication No.WO2007/008569, United States Published Patent Application Nos.2011/0039470 and 2012/0251863, and U.S. Pat. No. 7,581,932 allincorporated by reference for all purposes. See also, U.S. Pat. Nos.6,855,652, 7,125,461 and 7,318,873, and United States Published PatentApplication Nos. 2003/0039792, 2010/0289242, 2011/0278802, and2009/0202294, incorporated by reference for all purposes.

The present application also is related to and incorporates by referencefor all purposes Great Britain Patent Application No. 1318595.4, filedOct. 21, 2013.

SUMMARY OF THE INVENTION

One or more of the above needs are met by the present teachings whichcontemplate improved structures and methods that can be employedadvantageously for sealing, baffling and/or structurally reinforcingvarious articles, and particularly for structurally reinforcingtransportation vehicles, such as automotive vehicles. The materials ofthe present teachings also find application in a number of otherapplications as will be gleaned from the following discussion. That is,the present teachings relate generally to composite materials. As oneexample, the present teachings relate to fibrous composite materialsthat employ a distributed phase (e.g., a fibrous phase) and a thermosetpolymeric material. The material offers the benefit of mechanicalproperties typically achieved through the use of thermoset polymericmaterials (e.g., a polyurethane material) as some or all of a matrixphase of a composite. However, the material has a number of physicalattributes that make it suitable for handling, processing and/orpost-useful life reclamation, recycling, and/or re-use.

The teachings herein relate to a composite article. The compositearticle may be in a form suitable for use as part of a baffle and/orstructural reinforcement for a transportation vehicle. The compositearticle may include at least two phases. For example, it may include adistributed phase and a matrix phase within which the distributed phaseis distributed. The distributed phase in the composite article mayinclude a plurality of segmented forms selected from fibers, platelets,flakes, whiskers, or any combination thereof. The polymeric matrix inthe composite article in which the distributed phase is distributed mayinclude at least about 25% by weight of the polymeric matrix of asubstantially thermoset polymer which may be a reaction product of anisocyanate and a polyol.

The teachings herein also relate to a method for making a compositearticle. In general, a method in accordance with the present teachingsmay employ a step of contacting a plurality of segmented forms providedfor defining a distributed phase with a thermoset polymer (e.g., apolyurethane), that is in a softened state (e.g., in a liquefied moltenstate). For instance, a method in accordance with the present teachingsmay employ forming a composite material by extrusion, injection molding,pultrusion, or a combination of such processes. Thus, it is envisionedfor the teachings herein that there is method of making the compositearticle that includes contacting an isocyanate/polyol reaction productmaterial during a step of extrusion, injection molding, pultrusion orany combination thereof. The contacting may be only after the reactionhas completed between the isocyanate and polyol (e.g., only after thereaction of isocyanate and polyol). Thus it is possible that the methodherein will involve no chemical reaction between any isocyanate andpolyol reactants that occurs within an injection molding machine and/oran extruder. That is, the method may include advancing a thermosetpolymer along a rotating feed screw within a barrel of a polymericmaterial shaping apparatus.

Composites that are made in accordance with the present teachings can beemployed as some or all of a consolidated fibrous composite materialinsert and/or overlay. The fibrous material composites herein mayinclude a distributed phase and a matrix phase, wherein the distributedphase includes at least one elongated fiber arrangement in order todefine a consolidated fibrous insert for a carrier. The carrier, theconsolidated fibrous insert and/or overlay, or each may have an outersurface. The composite, the insert and/or overlay, or each may includeat least one elongated fiber arrangement having a plurality of orderedfibers (e.g., organic and/or inorganic fibers) that may be distributedin a predetermined manner in a polymeric material matrix. The polymericmaterial matrix may include a thermoset resin material as describedgenerally, or as described in any of the particular illustrativematerials herein. The composites of the present teachings may beemployed alone for defining a carrier for the baffles and/or structuralreinforcements of the present teachings. The composites of the presentteachings may be employed as a fibrous insert adjoining (e.g., in amanner to achieve as a continuous outer surface) a mass of the polymericmaterial (e.g., one that includes a polyamide such as Nylon, Nylon 6,Nylon 66, poly-butylene terephthalate, or any combination thereof,optionally being glass filled) for defining such a carrier. Thelocation, size, shape or any combination thereof, of the fibrous insertmay be selected to help improve one or more properties of the carrier inthe region where the insert is located. The carrier may carry anactivatable material over at least a portion of the outer surface of thecarrier. For example, the activatable material may be activated by heat(e.g., heat from a paint bake oven, such as an automotive paint bakeoven, or by induction heating) to foam, expand, adhere and/or cure.

The teachings herein further provide for composites comprising a mass ofpolymeric material having an outer surface and including a firstpolymeric material, at least one fibrous material overlay having anouter surface and including at least one elongated fiber arrangementhaving a plurality of ordered fibers, the at least one fibrous insert;and a second polymeric material layer located in between and in directplanar contact with each of the mass of polymeric material and at leastone fibrous material overlay.

The composite may include a single mass of polymeric material, which maybe a polyethylene material. The composite may include exactly twofibrous material overlays. The composite may include at least two secondpolymeric layers. The composite may include at least four secondpolymeric layers. The composite may include exactly four secondpolymeric layers. The second polymeric layer may be a film. The mass ofpolymeric material may include a polyethylene material. The at least onefibrous material overlay may include glass fibers.

The teachings herein also provide for a method comprising forming thecomposites described herein in a heated press.

The teachings herein further provide for a device comprising anelongated pultruded thermoset polymer carrier, a sealant materiallocated into direct planar contact with a portion of the carrier, andone or more film layer portions located in direct planar contact withthe carrier.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side sectional view of a portion of one illustrative part inaccordance with the present teachings.

FIG. 2 is a side sectional view of a portion of another illustrativepart in accordance with the present teachings.

FIG. 3 is a side sectional view of a portion of yet another illustrativepart in accordance with the present teachings.

FIG. 4a is a top perspective view of one illustrative carrier inaccordance with the present teachings.

FIG. 4b is a bottom perspective view of the carrier of FIG. 4 a.

FIG. 5 is an exploded perspective view of one illustrative lay-up of afibrous insert of the present teachings.

FIG. 6a is a perspective view of an illustrative fibrous insert inaccordance with the present teachings.

FIG. 6b is a perspective view of an illustrative part incorporating thefibrous insert of FIG. 6 a.

FIG. 7a is a perspective view of another illustrative fibrous insert inaccordance with the present teachings.

FIG. 7b is a perspective view of an illustrative part incorporating thefibrous insert of FIG. 6 a.

FIG. 8 is a schematic illustrating the formation of an illustrative partin accordance with the present teachings.

FIG. 9 is an illustrative example of a profile of an elongated article(e.g., a carrier) having an illustrative overlay in accordance with thepresent teachings.

FIG. 10 is a schematic of a system for making an article in accordancewith the present teachings.

FIG. 11A is a perspective view of an illustrative article in accordancewith the present teachings.

FIG. 11B is a rear perspective view of the article of FIG. 11A.

FIG. 11C is a side profile view of the article of FIG. 11A.

DETAILED DESCRIPTION

The present teachings meet one or more of the above needs by theimproved devices and methods described herein. The explanations andillustrations presented herein are intended to acquaint others skilledin the art with the teachings, its principles, and its practicalapplication. Those skilled in the art may adapt and apply the teachingsin its numerous forms, as may be best suited to the requirements of aparticular use. Accordingly, the specific embodiments of the presentteachings as set forth are not intended as being exhaustive or limitingof the teachings. The scope of the teachings should, therefore, bedetermined not with reference to the above description, but shouldinstead be determined with reference to the appended claims, along withthe full scope of equivalents to which such claims are entitled. Thedisclosures of all articles and references, including patentapplications and publications, are incorporated by reference for allpurposes. Other combinations are also possible as will be gleaned fromthe following claims, which are also hereby incorporated by referenceinto this written description.

This application claims the benefit of the priority date of U.S.Provisional Application Ser. No. 62/308,691, filed Mar. 15, 2016, thecontents of that application being hereby incorporated by referenceherein for all purposes.

The present application is related to the teachings of PCT ApplicationNo. PCT/US14/070853, filed Dec. 17, 2014; U.S. Provisional ApplicationSer. No. 61/916,884, filed on Dec. 17, 2013; and PCT Application No.PCT/US14/61531, filed Oct. 21, 2014, the contents of these applicationsbeing hereby incorporated by reference for all purposes.

This application is related to U.S. Provisional Application Ser. No.62/130,832, filed Mar. 10, 2015; U.S. Provisional Application Ser. No.62/183,380, filed Jun. 23, 2015; U.S. Provisional Application Ser. No.62/294,160, filed Feb. 11, 2016; and U.S. Provisional Application Ser.No. 62/296,374, filed Feb. 17, 2016; all of which are incorporated byreference for all purposes.

The teachings contemplate the possibility that a structure may befabricated using a thermoset material in accordance with the teachingsgenerally herein. In particular, the structure may be made from athermoset material in accordance with the present teachings that isreinforced with a reinforcement phase. The reinforcement phase may bedistributed in a matrix of the thermoset material (e.g., a polyamide asdescribed and/or a resin material as described). For example, thereinforcement phase may be at least a majority (by volume) of the totalmaterial. It may be greater than about 60% by volume or greater thanabout 70% by volume. It may be below about 90% by volume, below about80% by volume, or below about 70% by volume. Any reinforcement phase maybe distributed randomly, generally uniformly, and/or in one or morepredetermined locations of an article. The reinforcement phase maycomprise the thermoset material.

The fibrous composite materials may be employed as a portion of anothercomposite material. For example it may be employed as an insert (e.g., afibrous insert) and/or an overlay (e.g. sheet) of a composite thatincludes one or more other materials.

The teachings herein relate to a composite article. The compositearticle may be in a form suitable for use as part of a baffle and/orstructural reinforcement for a transportation vehicle. The compositearticle may be in a form suitable for use as a panel structure. Thecomposite article may be in a form suitable for use as a buildingconstruction material, as a furniture material, as a sporting goodmaterial (e.g., for skis, snowboards, bicycles, bats, tennis rackets orthe like) or as protective gear material (e.g., for police shields,armored vehicle panels, or the like). The fibrous composite materials ofany composite article herein may include a single phase or may includeat least two phases. For example, it may include a distributed phase anda matrix phase within which the distributed phase is distributed. Thedistributed phase in the composite article may include a plurality ofelongated (e.g., in a ratio of at least 2:1 as between a major and minordimension of the form) segmented forms selected from fibers, platelets,flakes, whiskers, or any combination thereof. For fibers employedherein, the fibers may be employed in the distributed phase is in theform of a random distribution, a weave, a non-woven mat, a plurality ofgenerally axially aligned fibers (e.g., a tow), a plurality of axiallyintertwined fibers (e.g., a yarn) or any combination thereof. Aplurality of individual fibers may thus be in a generally orderedrelationship (e.g., according to a predetermined pattern) relative toeach other.

The ratio by weight of polymeric matrix to the distributed phase may berange from about 1:10 to about 100:1 (e.g., it may range from about 1:5to about 10:1, about 1:3 to about 5:1, about 1:2 to about 2:1).

The balance of the material of the fibrous composite material may be thedistributed phase. The balance of the material of the composite materialmay include the distributed phase in addition to another phase and/ormaterial.

The distributed phase may include one, two or more different materials.For instance it may include a single form (e.g., a single elongatedsegment form), or a plurality of different forms (e.g., a plurality ofelongated segment forms). At least about 25%, 33%, 50%, 67%, 85% byweight of the distributed phase may be fibers. The distributed phase mayhave less than about 5%, 3%, or even 1% by weight of a form other than afiber.

The fibrous material, which may be formed as a distributed phase, mayinclude an organic material, an inorganic material or a combination ofeach. The material may be a naturally occurring material (e.g., arubber, a cellulose, sisal, jute, hemp, or some other naturallyoccurring material). It may be a synthetic material (e.g., a polymer(which may be a homopolymer, a copolymer, a terpolymer, a blend, or anycombination thereof)). It may be a carbon derived material (e.g., carbonfiber, graphite, graphene, or otherwise). The distributed phase may thusinclude fibers selected from (organic or inorganic) mineral fibers(e.g., glass fibers, such as E-glass fibers, S-glass, B-glass orotherwise), polymeric fibers (e.g., an aramid fiber, a cellulose fiber,or otherwise), carbon fibers, metal fibers, natural fibers (e.g.,derived from an agricultural source), or any combination thereof. Theplurality of elongated fibers may be oriented generally parallel to eachother. They may be braided. They may be twisted. Collections of fibersmay be woven and/or nonwoven.

The fibrous material may include a plurality of fibers having a lengthof at least about 1 cm, 3 cm or even 5 cm or longer. Fibers may have anaverage diameter of about 1 to about 50 microns (e.g., about 5 to about25 microns). The fibers may have a suitable sizing coating thereon. Thefibers may be present in each layer, or in the fibrous insert generally,in an amount of at least about 20%, 30%, 40% or even 50% by weight. Thefibers may be present in each layer, or in the fibrous insert generally,in an amount below about 90%, 80%, or even about 70%, by weight. By wayof example, the fibers may be present in each layer, or in the fibrousinsert, in an amount of about 50% to about 70% by weight. Fiber contentsby weight may be determined in accordance with ASTM D2584-11. The fibersmay comprise the thermoset polymeric material as described herein.

Tapes, sheets (e.g., films), and profiles for use in one or more of theportions of a fibrous composite material herein may be made byextrusion, pultrusion or otherwise. Examples of such processes can befound in U.S. Provisional Application Nos. 62/130,908, filed Mar. 10,2015; U.S. Provisional Application No. 62/200,380, filed Aug. 3, 2015;and U.S. Provisional Application No. 62/296,378, Filed Feb. 17, 2016,all incorporated by reference herein for all purposes. In this manner,it may be possible to achieve ordering of the fibers in the profiles,tapes and/or sheets. The profiles, tape and/or sheet may be formed fromthe thermoset polymer material. The tape and/or sheet may include afibrous phase or may alternatively be substantially free of any fibrousphase. The thermoset polymeric material may be formed into fibers whichmay then form the tape and/or sheet. A method herein may include a stepof impregnating a fibrous mass with the material of the polymeric matrixand passing the resulting impregnated material through a die (e.g., aheated die) or other structure having an opening so that the fibrousmass is coated with a generally continuous mass of the material of thepolymeric matrix. In this manner, it is also possible to achieve desiredordering of fibers relative to each other. The composite materials maybe formed by keyed extrusion, whereby a heat staking process is used toattach a mechanical fastener, which may located into a channel formedduring the extrusion process. Alternatively, the fastener may beattached at a location with no channel formation.

The fibrous composite materials of the present teachings may include oneor more layers (e.g., they may have 2, 3, 4, 6, or 15 or more layers).The layers may be consolidated in the sense that they include aplurality of individual fibers or other segmented forms of a distributedphase, which may be distributed in a cohesive mass of the polymericmatrix material. Multiple layers may be consolidated together so that acohesive mass, including the multiple layers, is formed. The multiplelayers may be consolidated so as to form a predetermined shape in theform of a three-dimensional shaped insert. For instance, the fibrousinsert may employ a plurality of layers that include a plurality ofelongated fibers (e.g., having a length of at least 1 cm, 3 cm or even 5cm or longer) that are oriented generally parallel or generallyunidirectionally to each other and are distributed in a generallycontinuous polymeric matrix (e.g., in a continuous matrix of the secondpolymeric material). A shaping operation (e.g., thermoforming, molding,passing through a die, rolling, or otherwise) may be performed.

The fibers may be present in an amount, a distribution, or both forreinforcing the composite article by the realization of an increase ofone or more mechanical properties selected from ultimate tensilestrength, elongation, flexural modulus, compression modulus, orotherwise, as compared with the corresponding property of the polymermatrix material alone.

The fibrous composite materials of the present teachings may be such sothat the distributed phase is distributed in the polymeric matrixmaterial in an ordered arrangement, in a substantially homogenousarrangement or both. It is possible that the distributed phase isdistributed in the polymeric matrix material in a random arrangement.The individual fibers may be distributed in a predetermined orderedarrangement within the matrix of polymeric material so that at least aportion of the fibers are ordered in their arrangement (e.g., in agenerally ordered relationship relative to each other, such as generallyparallel or unidirectional or otherwise generally axially aligned), andthus are not randomly distributed in the polymeric matrix material.

Turning in further detail to the materials that may be employed in thepresent teachings, a variety of materials having thermoset thermalcharacteristics may be suitable. In general, the teachings herein extendalso to certain thermoset polymers (e.g., polyamides, such as Nylon 6,or Ultratape from BASF). The materials may be employed alone, as amatrix material of a multi-phasic material (e.g., along with areinforcement phase, such as carbon fibers, glass fibers, polymericfibers, natural fibers, or some other segmented form, as describedelsewhere herein). It may be employed as a layer of a laminate, as coreor a sheath of a core/sheath elongated material, as a core or a shell ofa core/shell material, or otherwise.

The materials useful in the present teachings may have a T_(g) belowabout 200° C., below about 170° C., below about 160° C., below about150° C., below about 140° C., as measured by differential scanningcalorimetry according to ASTM E1356-08(2014). The material of thepresent teachings may have a glass transition temperature as measured bydifferential scanning calorimetry according to ASTM E1356-08(2014) of atleast about 100° C., at least about 120° C., or at least about 130° C.

The polymeric material may exhibit one or any combination of thefollowing characteristics: a tensile strength at yield (according toASTM D638-14) of at least about 15 MPa (e.g., at least about 30 MPa, atleast about 45 MPa, at least about 60 MPa), a tensile elongationstrength at break (according to ASTM D638-14) of at least about 40 MPa(e.g., at least about 45 MPa or even at least about 55 MPa); anelongation at break (according to ASTM D638-14) of at least about 15%(e.g., at least about 20%, 25% or 30%); and/or a tensile modulus ofelasticity (according to ASTM D638-14) of at least about 0.5 GPa, (e.g.,at least about 1 GPa, at least about 1.8 GPa, or even at least about 2.7GPa); the ability to withstand a load of at least 800 lbs over a periodof at least 6 milliseconds (according to ASTM D2763).

In general, it may also be possible to employ one or more reactants thatpermit an optional delayed cross-linking reaction to occur. For example,one or more of the reactants may include one or more moieties that arecapable of reacting (e.g., in the presence of a certain stimulus, suchas further heating and/or some other form of a predeterminedelectromagnetic radiation (e.g., infrared, ultraviolet, microwave orotherwise) for achieving cross-linking of a molecule with in itselfand/or with an adjoining molecule. Desirably such radiation affordscross-linking while maintaining a resulting article made by additivemanufacturing to remain below its T_(g). Thus, it may be possible thatcrosslinking may be realized within and/or between adjoining layers.Thus, the teachings contemplate an optional step of causing at least aportion of an article made with the teachings to include cross-linking,such as by causing a cross-linking reaction to occur (e.g., bysubjecting feed material and/or the resulting article to electromagneticradiation as described).

The teachings herein make advantageous use of resin materials for use invarious applications, such as in the construction, appliance, defense,sporting goods, and/or transportation industries. By way of example,resin materials of the teachings find application in transportationvehicle components, such as structural reinforcements, baffle devices,sealing devices, panels (e.g., wall panels, automotive body panels, roofpanels, etc.), brackets, beams (e.g., cross-vehicle beams, such as beamsuseful for supporting instruments of an instrument panel), module frames(e.g., a frame upon which a plurality of components can be mounted,either before, during and/or after assembly of the frame into a vehiclestructure).

It is also possible that a portion of the intended distributed phasematerial is contacted with reactants prior to any reaction to form thethermoset polymer reaction product of the present teachings. Forexample, it may be possible that the intended distributed phase materialis contacted with either or both of an isocyanate and polyol reactant(e.g., in a liquid state) prior to reaction to form the thermosetpolymer reaction product. For example, a mass of fibers may beinfiltrated with a liquid isocyanate reactant, a liquid polyol reactantor both. Thereafter, any remaining reactant may be introduced (alongwith exposure to any necessary heat and/or pressure) for bringing abouta reaction to form the thermoset polymer reaction product in situ withinthe mass of fibers. Use of the resins described herein as pultrusionpolymers, when in a fluidic state, are able to provide a surprisinglygood infiltration of a mass of fibers for providing a cohesive matrixwithin which the fibers are distributed. Examples of suitable isocyanatematerials may include modified polymeric MDI (diphenylmethanediisocyanate), an example of which is sold under the designationSUPRASEC® 9700 available from Huntsman. Examples of suitable polyols mayinclude those sold under the designation Rimline® also available fromHuntsman. The isocyanate may have a relatively low viscosity of fromabout 10 to about 500 mPa·s at 25° C. or even from about 20 to about 100mPa·s at 25° C. (in accordance with ASTM D4889). Such low viscosity mayallow for increased loading of the fibers of the distributed phase. Theisocyanate may have a functionality of from about 2.0 to about 3.0, oreven from 2.5 to 2.9. The isocyanate may have a free isocyanate contentof from about 15% to about 40%, or even from about 20% to about 30%.

A method for making an article in accordance with the present teachingsmay be performed in a continuous manner. For example, fibrous materialfrom a continuous supply (e.g., a reel of the desired fibrous material(e.g., in its desired form, such as a strand, a yarn, a weave, nonwovenmat, or otherwise as described herein) for use as the distributed phase)may be fed continuously to and through a die, which may be an extrusionor pultrusion die. The fibrous material may be contacted (e.g., by wayof a suitable coating operation, such as roll coating, or otherwise)with the thermoset polymer reaction product prior to or at the time whenthe fibrous material is passed through the die. The fibrous material maybe contacted (e.g., by way of a suitable coating operation, such as rollcoating, or otherwise) with the reactants for the thermoset polymerreaction product prior to or at the time when the fibrous material ispassed through the die. Upon exiting the die, a composite mass results.The fibrous material may thus form a distributed phase within thecomposite mass. The mass may be cut, shaped or otherwise subjected toanother (e.g., a secondary) operation to render a composite articlesuitable for use for an intended application.

It may be possible also that a step of co-extrusion may be employed. Thestep of co-extrusion may include a step of passing a composite mass,such as described above, through a die, while also feeding a supply ofbase material through the die. The base material may be a polymericmaterial, a metal material or otherwise. Conditions may be maintainedwhile the materials are passed through the die so that the compositemass becomes bonded to (e.g., mechanically, adhesively, covalently, orany combination thereof), to the resulting shaped base material. Forexample, it may be possible that the heat from the base material whileit is processed through the die, or essentially immediately thereafter,may be sufficiently hot to cause the thermoset polymer reaction productto fuse with or otherwise bond to the base material. A shaping step maybe included which may allow for a plurality of layers to be assembled ina press which may or may not be a heated press.

As can be appreciated, a variety of suitable composite profiles arepossible as a result of the teachings. The profiles may include alongitudinal axis. The composite profiles may be symmetric or asymmetricrelative to the longitudinal axis. The composite profiles may includeone or more longitudinally oriented ribs. The composite profiles mayinclude one or more transversely extending flanges. The compositeprofiles may include both flat portions and curved portions. Thecomposite profiles may have one or more outer surfaces. The compositeprofile may have one or more inner surfaces. The composite profiles mayinclude a composite overlay that includes or consists of a compositemass of the present teachings. The composite profiles of the teachingsmay include a composite overlay that includes or consists of a compositemass of the present teachings. The composite overlay may cover all orpart of an outer or inner surface. The composite overlay may include orconsist of a composite mass of the present teachings may define all orpart of a rib, a flange (e.g., a transversely oriented flange) or both.The composite profiles may include a composite mass that is at leastpartially or even completely embedded within the base material over someor all of the length of the composite profile. The composite profile mayinclude an extruded profile structure defining a mechanical attachmentfor securing the profile to another structure (e.g., such as isdisclosed in U.S. Pat. No. 7,784,186 (incorporated by reference; see,e.g., FIGS. 4-8 and associated written description)). The compositeprofile may also have one or more push pin type fasteners such asdisclosed in U.S. Pat. No. 7,784,186 (incorporated by reference; see,e.g., FIGS. 1-3 and associated written description). Any of the abovecan be employed for use as an extruded carrier for a structuralreinforcement and/or baffle (e.g., for a transportation vehicle).

For use as an extruded carrier for a structural reinforcement and/orbaffle (e.g., for a transportation vehicle), there may also be employedan activatable material or at least a portion of an outer surface of thecarrier.

The teachings also envision a possible manufacturing system that may beemployed for an extrusion operation in accordance with the presentteachings. Raw material for forming a base polymeric material body arefed into a hopper associated with an extruder. The extruder may have adie through which the raw material is passed to form a shaped bodyprofile (e.g., an extruded profile). The shaped body profile may becooled (e.g., by a vacuum cooler) to a desired temperature (e.g., belowthe softening point of the material, so that it retains its shapedstate). A feed system may feed a fibrous material (e.g., by way ofrollers) to a suitable device for applying a matrix material fordefining a composite fibrous material (e.g., a roll coater). At suchdevice, the material for forming a polymeric matrix is contacted withthe fibrous material. A suitable device for defining a shape of thefibrous composite material may be employed, such as a forming roller, aheated press, or another suitable extrusion and/or pultrusion typeshaping device). The forming roller or other suitable device may alsoserve to help join the fibrous composite material with the shaped basebody profile.

Upon joinder the resulting overall composite may be cooled (e.g., by acooling tank). Optionally, if to be employed for use as a carrier for abaffling and/or structural reinforcement application, the resultingoverall composite may be advanced by a conveyor device (e.g., a pullingor pushing device). The line speed may be about 1.5 m/minute or even 2.5m/minute. The pull force may be less than 40 tons, less than 20 tons,less than 12 tons or even less than 6 tons. An activatable material(e.g., a polymeric heat activatable sealant, acoustic foamable material,and/or structural reinforcement material) may be applied to thecomposite by an extruder (e.g., a cross head extruder). Thereafter, theresulting composite (with or without the activatable material on it) maybe cut by a suitable cutting device (e.g., a traveling cut-off saw). Byway of illustration, without limitation, the raw material may be a glassfilled Nylon® heated to about 260° C. Upon exiting the cooler, thetemperature may be about 150 to about 175° C. Upon exiting the coolingtank the composite may be at a temperature of about 120° C. At the timeof passing the extruder, the temperature may be about 90-95° C. Thecross-head extruder may extrude one or more masses of a heat activatableepoxy-based structural foam, such as the L-55xx series of materials,available from L&L Products, Inc. See, e.g., U.S. Pat. No. 7,892,396,incorporated by reference for all purposes (an illustrative compositionis shown therein at Table I). The heat activatable material may beactivatable to expand by foaming, and adhere to an adjoining surface(e.g., a wall defining a part of a vehicle, such as a wall defining avehicle cavity). The activation may occur upon exposure to the heat of apaint bake oven or induction heating device, following an electrocoatingdeposition step. The resulting activated material may be expanded to atleast about 50%, 100%, 200%, 400%, 600%, or even 1000% of its originalvolume. The resulting activated material may be expanded from itsoriginal volume, but in an amount that is below about 2500%, 2000% oreven below about 1500% of its original volume.

The fibrous composite material of the present teachings may be employedin any of a variety of possible forms. It may be employed as an overlayon top of a body (e.g., a shaped polymeric body). It may be employed asan insert (e.g., for forming a continuous adjoining surface with ashaped polymeric body). It may be an encapsulated insert within a shapedpolymeric body. It may be employed as a substitute for sheet metal. Itmay be employed as a substitute for a tube or other generallycylindrical element (e.g., a roll tube or a hydroformed tube). Thefibrous composite material may be a patch, a strip, a wrap, or the likethat may be used to provide localized reinforcement to another componentof an assembly (e.g., a beam that receives some load). The fibrouscomposite material may be rolled into a tubular shape (e.g., for use asor with cross-car beams, side intrusion or impact beams, or otherautomotive parts). The composite material may form two or moreintegrally formed I-beams (see for example FIGS. 10-11). The fibrouscomposite material may be thermoformed into a desired shape (e.g., for aroof bow, bumper, or other automotive part). The fibrous compositematerial may be shaped to provide a structure and support forsubcomponents of an assembly. For example, the fibrous compositematerial may be shaped to form a door inner module, which may provide aninternal structure within a vehicle door, which may also provide an areafor mounting and/or supporting subcomponents within the door (e.g., amotor for actuating movement of the windows, the locking mechanism, awire harness, speaker system, ventilation components, mirror controls,demister, and the like).

In one aspect of the present teachings there is contemplated a baffleand/or a structural reinforcement for an article. The baffle and/orstructural reinforcement includes a carrier that includes a mass ofpolymeric material having an outer surface and including a firstpolymeric material (e.g., a first thermoset material). The carrier maybe made of a single polymeric material, or a plurality of polymericmaterials. The carrier may include a fibrous composite material of thepresent teachings. That is, the carrier may include a distributedsegmented form phase and a polymeric matrix phase.

By way of illustration, the carrier may employ at least one consolidatedfibrous insert (which may have a predetermined ordering of fibers withinthe insert and/or may have a three dimensional shaped configuration)having an outer surface. The carrier may be a polymeric material layerlocated adjacent one or more additional layers including a fibrous layerand a thermoset polymer layer. The fibrous material may include at leastone consolidated fibrous insert including at least one elongated fiberarrangement (e.g., having a mass of continuous fibers, which may be inan ordered arrangement, such as by being generally axially alignedrelative to each other) distributed in a cohesive mass of a secondpolymeric material (e.g., a second thermoset material). The fibrousinsert and associated second polymeric material may adjoin the mass ofthe first polymeric material in a predetermined location for carrying apredetermined load that is subjected upon the predetermined location.The fibrous insert, the second polymeric material and the mass of firstpolymeric material include compatible materials, structures or both, forallowing the fibrous insert to be at least partially joined to (e.g.,form a single phase with or be miscible in) the mass of the firstpolymeric material. The structural reinforcement may also include a massof activatable material selectively applied over at least a portion ofone or both of the outer surface of the mass of the polymeric materialor the fibrous insert (e.g., on exterior peripheral surface of thecarrier, within a cavity of the carrier, or both). The mass ofactivatable material is capable of activation for expansion by anexternal stimulus (e.g., heat, moisture, radiation or otherwise) and iscapable of curing to form an adhesive bond to at least one surface ofthe article. Desirably the outer surface of the fibrous insert may be atleast partially co-extensive and continuous with the outer surface ofthe mass of polymeric material.

Materials for a carrier body herein may be a polyamide, a polyolefin(e.g., polyethylene, polypropylene, or otherwise), a polycarbonate, apolyester (e.g., polyethylene terephthalate), a thermoset polyurethane,or any combination thereof. It may be preferred to employ a polyamide(e.g., polyamide 6, polyamide 6,6, polyamide 9, polyamide 10, polyamide12 or the like). The materials of a carrier body and any overlay and/orinsert may be generally compatible with each other in that they arecapable of forming a mechanical or other physical interconnection (e.g.,a microscopic interconnection) between them, they are capable of forminga chemical bond between them, or both. For example, the first and secondmaterials may be such that they fuse together (e.g., in the absence ofany adhesive) when heated above their melting point and/or theirsoftening point. The carriers may also be overmolded with a secondarymaterial, such secondary material may be a polymeric material such as apolyolefin, a polyamide, a polyester, a polyurethane, a polysulfone, orthe like, or an expandable polymer (e.g., a structural foam or anacoustic foam).

The polymeric body of any carrier may include a polymeric material thatmay be filled with chopped fibers (e.g., chopped glass fibers), whichmay be present in amount of about 25 to about 40 (e.g., about 30 toabout 35) weight percent chopped fibers. The average length of suchfibers may be below about 20 mm, below about 10 mm or even below about 5mm. They may be randomly oriented. The first and second materials may befree of any metallic materials.

A fibrous insert and/or layer may include one or more layers (e.g., theymay have 2, 3, 4, 6, or 15 or more layers) that are consolidated in thesense that they include a plurality of individual fibers that aredistributed in a cohesive mass of the second polymeric material. Theindividual fibers may be distributed in a predetermined orderedarrangement within a matrix of the second polymeric material. Preferablyat least a portion of the fibers are ordered in their arrangement (e.g.,in a generally ordered relationship relative to each other, such asgenerally parallel or unidirectional or otherwise generally axiallyaligned), and thus are not randomly distributed in the second polymericmaterial. Multiple layers may be consolidated together so that acohesive mass, including the multiple layers, is formed. The multiplelayers may be consolidated so as to form a predetermined shape in theform of a three-dimensional shaped insert. It is also possible that afilm or intermediate layer may be located in between one or more of themultiple layers. For instance, the fibrous insert may employ a pluralityof layers that include a plurality of elongated fibers (e.g., having alength of at least 1 cm, 3 cm or even 5 cm or longer) that are orientedgenerally parallel or generally unidirectionally to each other and aredistributed in a generally continuous polymeric matrix (e.g., in acontinuous matrix of the second polymeric material). The fibers may bemineral fibers (e.g., glass fibers, such as E-glass fibers, S-glass,B-glass or otherwise), polymeric fibers (e.g., an aramid fiber, acellulose fiber, or otherwise), carbon fibers, metal fibers, naturalfibers (e.g., derived from an agricultural source), or otherwise.Desirably the fibers are glass fibers. The plurality of elongated fibersmay be oriented generally parallel to each other. They may be braided.They may be twisted. Collections of fibers may be woven and/or nonwoven.The fibers may have an average diameter of about 1 to about 50 microns(e.g., about 5 to about 25 microns). The fibers may have a suitablesizing coating thereon. The fibers may be present in each layer, or inthe fibrous insert generally, in an amount of at least about 20%, 30%,40% or even 50% by weight. The fibers may be present in each layer, orin the fibrous insert generally, in an amount below about 90%, 80%, oreven about 70%, by weight. By way of example, the fibers may be presentin each layer, or in the fibrous insert, in an amount of about 50% toabout 70% by weight. Fiber contents by weight may be determined inaccordance with ASTM D2584-11. Tapes and/or sheets for the layers of thefibrous insert may be made by extrusion, pultrusion or otherwise. Inthis manner, it may be possible to achieve ordering of the fibers in thetapes and/or sheets. The method herein may include a step ofimpregnating a fibrous mass with the material of the polymeric matrixand passing the resulting impregnated material through a die (e.g., aheated die, heated to a temperature of less than about 50° C. at a coolentrance, greater than about 160° C., greater than 190° C., and lessthan 250° C.) so that the fibrous mass is coated with a generallycontinuous mass of the material of the polymeric matrix. In this manner,it is also possible to achieve desired ordering of fibers relative toeach other.

Each layer of the fibrous insert may be in the form of a sheet, a tapeor otherwise. Fibers in the sheet and/or tape preferably may have anordered relationship relative to each other. For example, the fibers maybe generally parallel with each other and/or oriented unidirectionally.When consolidating multiple layers of sheet, tape or other form of layerto form a multi-ply fibrous insert, it is preferred that at least onelayer of the fibrous insert exhibits an ordered relationship, as opposedto a random relationship, such as is found in fiber mats, whichtypically employ chopped fibers that are randomly laid across eachother.

It is possible that the layers of the fibrous insert are provided asbeing wound on a reel. Each layer may have a thickness of at least about0.1 mm or at least about 0.2 mm. Each layer may have a thickness belowabout 0.5 mm or below about 0.4 mm. For instance, each layer may beabout 0.2 to about 0.3 mm in thickness. Some or all of the individuallayers may be anisotropic in its mechanical properties. For example, itmay exhibit a relatively high flexural modulus and/or strength in alongitudinal direction, but a lower flexural modulus and/or strength ina transverse direction, or vice versa.

The fibrous material may include a plurality of woven strips. Forexample, it may include a plurality of strips that are cross woven, eachstrip having a width of at least about 1 mm, at least about 2 mm, oreven at least about 3 mm. It may include a plurality of strips that arecross woven, each having a width below about 10 mm, below about 8 mm, oreven below about 6 mm. The woven strips may be held together by apolymeric matrix material, e.g., a continuous matrix of the polymericmaterial of the insert. Thus, the strips are fixed in a predeterminedposition relative to each other by virtue of the polymeric material. Itis preferred that at least some of the strips may each include aplurality of elongated fibers arranged in an ordered relationshiprelative to each other, desirably within a continuous matrix ofpolymeric material. However, it is possible that one or more strips mayinclude fibers having a random orientation relationship relative to eachother, such as is derived from typical fiber mats. Strips for formingweaves may be made by slitting a tape, sheet or other form to anappropriate width to form strips. Alternatively, it may be possible thatthe strips are pultruded, extruded or otherwise formed (as describedherein) in the desired width.

The material defining the fibrous insert may exhibit a flexural strengthper ASTM D790-10 of at least about 450 MPa (e.g., it may range fromabout 500 to about 1100 MPa). The material of the fibrous insert mayexhibit a flexural modulus per ASTM D790-10 of at least about 5 GPa, 10GPa, 20 GPa, or even at least about 25 GPa (e.g., it may range fromabout 30 to about 35 GPa).

The fibrous insert may employ a fully densified polymer for thepolymeric matrix. The fibrous insert may have a void content that isbelow about 10% by volume of the insert, and more preferably below about5% or even below about 2% or 1% as measured by ASTM D2734-09. Thefibrous insert may have a density that is below about 40% the density ofsteel, below about 33% the density of steel, or even below about 25% thedensity of plain carbon steel.

The fibrous insert may be made to include a plurality of adjoininglayers. The adjoining layers may have fiber orientations that are thesame or different relative to each other. The fibrous insert may includea woven layer adjoining a non-woven layer. The fibrous insert mayinclude a woven layer adjoining another woven layer. The weave patternof woven layers within the fibrous insert may be the same or may varybetween such woven layers. The width of strips may vary betweenadjoining layers. The thickness of adjoining layers may be the same ordifferent.

Examples of weave patterns include plain weaves, twill weaves, orotherwise. Overlapping strips may be woven generally orthogonal to oneanother or at some other angle. The weave may include a plurality ofwarp and weft strips. The ratio of warp to weft strips may range fromabout 30:70 to about 70:30. For example it may be about 50:50. It ispossible that strips of the warp and weft members may have generally thesame width. The warp strip and weft strip widths may vary relative toeach other by 10%, 20%, 30% or more. The warp strip and weft stripwidths may vary relative to each other by less than about 70%, 60%, 50%or less.

Each adjoining layer of tape and/or sheet in the fibrous inserts hereinmay be oriented so that it has fibers (i.e., the fibers that areembedded in the polymeric matrix of the tape and/or sheet) aligned in adifferent predetermined direction relative to fibers of an adjoininglayer. Fibers in one layer may be generally at an angle relative tofibers in an adjoining layer (e.g., the axis of fiber orientation asbetween layers may differ from about 10 to about 90°, such as in theform of an X-ply). For example, one multiple layer structure may includeone layer that may have fibers oriented in a first direction of a firstplane, and an adjoining layer oriented with its fibers generally in asecond plane parallel to the first plane, but at an approximately 90degree angle.

Desirably each of the adjoining layers are joined together as a cohesivemass. For instance, each of the layers may be bonded together by thepolymeric material of the respective layers to form a series ofcontinuous layers. The layers may be bonded together in the absence ofany adhesive.

The fibrous composite material, such as in the form of a sheet or a tape(which may serve as a patch or a wrap), may be applied to controlfailure modes of certain components of an assembly which may be subjectto a load, to provide localized reinforcement, or both. For example, ahollow beam (e.g., having a rectangular cross section) receiving a loadfrom the top may have a tendency to shear. Strength may be improvedand/or the failure mode may be altered by adding a fibrous compositematerial as disclosed herein. The fibrous composite material may beattached to the hollow beam to alter its deformation characteristics(e.g., with the composite material being generally planar (or in planarcontact with a portion of the beam), acting as a shell around the beam,surrounding the beam as a wrap in a generally helical direction, as agenerally cylindrical or tubular structure outside or inside of thehollow beam, or another configuration). For example, a woven tape may beapplied along the side walls of the beam to help resist having a shearplane that arises substantially along the longitudinal axis of the beam(traveling through the middle of the part). The tape (or other formfibrous composite material) may be single ply or multi-ply, with acombination of fiber orientations (e.g., one layer having fibersgenerally oriented in the longitudinal direction, another layer havingfibers in an orientation that is at an angle relative to thelongitudinal direction (e.g., at 90 degrees, 45 degrees or otherwise)).The fiber directions may assist in resisting shear or may providecontrol and/or predictability in failure of the component (e.g., a beam)upon being subjected to a particular load. A secondary component may beapplied to further increase strength or alter the failure mode, such asanother fibrous layer having a different orientation, or may be a metal,a foam component (inside or outside of the hollow beam, for example), afibrous mat, or a ductile material (e.g., a rubber-like material).

The fibrous insert may have one or more structural features incorporatedtherein or attached thereto. For example, one or more fasteners may beemployed (e.g., one or more threaded fasteners). One or more lugs may beformed or integrated into the fibrous insert (e.g., for providing a gapfor the passage of a coating fluid). One or more rivets (e.g., aself-piercing rivet, a blind rivet or both) may be integrated into theinsert. One or more metal blanks may be integrated into the insert,which may be adapted to provide a location on a resulting part for spotwelding. One or more studs may be integrated into the insert (e.g.,having a base that may have apertures defined therein, which is locatedwithin or on a surface of the fibrous insert and which has a post (e.g.,a threaded post) that extends outward from the base). One or moremetallic panels, sheets, or pieces may be integrated into the insert orsecured thereto, such as for providing localized reinforcement.

One or more structural features may be incorporated into the insert (orother composite material) via selective heating, which may be conductiveheating. In accordance with the present teachings there is envisionedthat one or more assemblies may be made by selectively heating a portionof a structure having a wall (e.g., an outer wall of the fibrous insert)with a thickness to elevate at least a portion of the thickness of thewall to a temperature above the glass transition temperature of apolymer (e.g., a polyamide and/or a resin material as taught herein,which may be reinforced as described herein, such as with a fiber orother phase) that forms the wall. While the at least a portion of thethickness of the wall is above the glass transition temperature of thepolymer that forms the wall, an article is contacted with the structureat least partially within the heated region, optionally under pressure.Thereafter, upon heat leaving the heated region, the polymer that formsthe wall cools so that resulting polymer in contact with the article iscooled below the glass transition temperature. An adhesive bond therebyresults, with the article remaining attached to the structure by way ofthe bond. The above method may be employed to form an adhesive bondeither with or without an additional applied adhesive. That is, it maybe possible that the material of the structure, when heated above itsT_(g), and then cooled below it, will be capable of forming an adhesivebond directly with the contacted article. Moreover, the tenacity of thebond may be sufficient so as to obviate the need for any fastener forsecuring the article to the structure. One option for achieving a bondedassembly in accordance with the above may be to employ an adhesivelayer, wherein the adhesive layer (e.g., having a thickness below about5 mm, 4 mm, or 3 mm, and above about 0.05, 0.1 or about 0.5 mm) is madeof a resin material as described herein.

The structure may be any of a number of suitable forms. For example, itmay be an elongated beam. It may have a length and may be solid alongall or part of the length. It may have a length and be hollow along allor part of the length. The structure may have a wall thickness, measuredfrom a first exposed surface to a generally opposing exposed surface.The wall thickness may be at least about 0.5 mm, about 1 mm, about 2 mm,about 5 mm, about 10 mm, or about 20 mm. The wall thickness may be belowabout 100 mm, below about 80 mm, below about 60 mm, or below about 40mm.

The structure may have a predetermined shape. The shape may include oneor more elongated portions. The shape may include one or more hollowportions. The shape may include one or more walls that define at leastone cavity. The structure may include a plurality of portions eachhaving a different shape. The structure may be configured to define afascia, which optionally may be supported by an underlying structure.The structure may be configured to define a support that underlies afascia. The structure may have a panel configuration, e.g., aconfiguration that resembles a transportation vehicle (e.g., anautomotive vehicle) exterior body or interior trim panel.

The structure may be configured to receive and support one or aplurality of articles (e.g., transportation vehicle components), such asfor forming a module. By way of illustration the one or more articlesmay be selected from a bracket, a hinge, a latch, a plate, a hook, afastener (e.g., a nut, a bolt or otherwise), a motor, a componenthousing, a wire harness, a drainage tube, a speaker, or otherwise.

Heat may be applied in any suitable way. One approach may be to employlocalized heating. For example, it is possible to employ inductionheating for selectively heating at least a portion of theabove-described structure. To illustrate, it is possible that thestructure will be made with a polymer (e.g., a polyamide and/or a resinmaterial as taught herein, which may be reinforced as described herein,such as with a fiber or other phase), and will have a wall thickness. Ametallic item (which may be a component desired to be attached to thestructure) may be brought into proximity (which may or may not be incontacting relation) with the structure at the desired location ofattachment. An induction heating device may be brought into proximitywith the metallic item for heating the metallic item, which in turn willheat the structure in the affected location when power is supplied tothe induction heating device. Other heating devices may be employed aswell for achieving localized heating.

It is possible that time that elapses from the time the structure isinitially heated until when an article becomes attached to it by theabove steps may be relative short. For example, the operation may takeless than about 1 minute, less than about 30 seconds, or less than about15 seconds. It may take as low as about 1 second, about 3 seconds, orabout 5 seconds.

Another approach to forming an assembly in accordance with the presentteachings envisions forming a shaped part by heating a of mass materialin accordance with the teachings (e.g., a polyamide and/or a resinmaterial as taught herein, which may be reinforced as described herein,such as with a fiber or other phase) to a temperature above the T_(g) ofthe material. When at least a portion of the material is above theT_(g), pressure may be applied to the mass of material to define aconfigured part. For example, it may be thermoformed, molded, orotherwise shaped. The configured part may then be joined with anotherpart to form an assembly. The joinder of parts may be by an adhesivebond, by a mechanical connection (e.g., using a fastener, using a fittedjoint configuration, or both), or both. For example, without limitation,at least two generally complementary parts may be secured to each other.If one of the parts is made with a resin material as taught herein, theymay be joined together by attaching the parts while at least a portionof that part is above the T_(g) of the resin material, and then coolingto a temperature below the T_(g). Optionally, this approach may bemodified to include the employment of a layer of adhesive between theparts, wherein the adhesive layer (e.g., having a thickness below about5 mm, 4 mm, or 3 mm, and above about 0.05, 0.1 or about 0.5 mm) is madeof a resin material as described herein.

The parts may include dissimilar materials. For example, one part mayinclude a resin material of the present teachings. The other part mayinclude a polyurethane, a polyolefin (e.g., a polypropylene), apolyamide, an acrylate, a methacrylate, a polycarbonate, a polyester, orany combination thereof; the other part may include a thermosetmaterial; the other part may be made form a sheet molding compound or byreaction injection molding.

As indicated the fibrous inserts may have a predetermined shape. Theshape may be the result of one or more calculations performed during astep of computer simulation of a crash, a certain stress state orotherwise, and may be selected so as to provide additional localizedreinforcement in a predetermined region of the part that will besubjected to a predicted stress condition that is determined from suchcalculations. The fibrous inserts herein may include one or anycombination of a generally sinousoidal geometry over some or all of itslength, a pair of spaced apart walls that are joined together by a crosswall, one or more ledges and/or steps, a concave surface portion, aconvex surface region, or one or more apertures. As indicated, thefibrous inserts herein may have a three dimensional configuration, incontrast with a generally planar configuration.

The characteristics of the insert can vary from application toapplication. One benefit of the present teachings is that the layers ofthe insert can be selected to meet the needs of a particular application(e.g., in response to modeling by computer simulation (such as computercrash or stress state simulation)). The insert can be individually builtup to include a plurality of layers based upon the performance demandedby the application. Moreover, another benefit of the teachings herein isthat localized reinforcement can be achieved by locating the inserts inparticular locations that are indicated as requiring additional localreinforcement (e.g., in response to modeling by computer simulation(such as computer crash or stress state simulation)). The teachingsherein thus afford the skilled person with a surprisingly expandedability to selectively tune performance of structural reinforcements.The teachings also contemplate the use of modeling by computersimulation to determine the location at which a carrier is expected tocarry a predetermined load in a crash or under a certain stress state.Based upon the results of such modeling, the location at which a fibrousinsert should be located can be determined. Also, based upon the resultsof such modeling, the orientation of fibers and/or the selection ofrespective adjoining layers of tape or sheet in a fibrous insert can beascertained. Parts can thereafter be made that are based upon thedesigns resulting from such modeling. Methods employing such steps arethus within the present teachings as well.

The carriers of the structural reinforcements may be such that the outersurface of the fibrous insert is generally co-extensive with the outersurface of the mass of polymeric material. This may be over some or allof the perimeter of the fibrous insert. It is also envisioned that thefibrous insert may have opposing surfaces that are each exposed and thusvisible in the resulting part. For instance, the fibrous insert may havean exposed outer surface and an exposed inner surface. Thus, the fibrousinsert may adjoin the mass of polymeric material only along one or moreside edges of the fibrous insert. The resulting visible surfaces of thecarrier may be substantially free of knit lines or other imperfectionsthat could provide a source of localized weakening of the carrier.

The second polymeric may be applied directly onto the fibrous insert.The second polymeric material may be a liquid poured onto the fibrousinsert until the insert is saturated with the second polymeric material.The liquid absorbed by the fibrous insert may account for at least about30% and less than about 70% of the total weight of the insert aftersaturation. The saturated insert may polymerize at room temperature orwith the addition of heat, such that a rigid solid composite is formed.The resulting composite may then receive the first polymeric material bylocating the composite into a tool and molding the first polymericmaterial (which may be a nylon material) about the composite.

As appreciated from the above, the carrier may have (i) a polymericportion defined by the mass of first polymeric material, (ii) alocalized reinforcement portion defined by the at least one fibrousinsert, and (iii) an interface portion between the polymeric portion andthe localized reinforcement portion wherein the polymeric portion, theinterface portion and the localized reinforcement portion are agenerally continuous structure. The interface portion may include (i) aninterpenetrating network defined by the first and second polymericmaterials, (ii) chemical bonds between the first and second polymericmaterials, or both (i) and (ii).

One or more sides of the activatable material may be tacky. Though it isalso possible that one or more sides will be generally tack free to thetouch at room temperature. One or more mechanical fasteners may beemployed by attaching to or being formed integral with the activatablematerial, the carrier, or both.

Suitable materials that may be employed for the activatable materialinclude expandable materials and materials that do not expand. However,it is contemplated that the activatable material can be activated toform a foam. For instance, the material may be activated to form astructural foam (e.g., the material may include an epoxy ingredient).The material may be activated to form an acoustic foam. The material maybe activated to flow for purposes of sealing a region within a cavity.The material may include a combination of a material that is activatableto expand and a material that is not activatable to expand.

The structural reinforcement of the present teachings may be employedfor structurally reinforcing an article, such as by locating thestructural reinforcement within a cavity of the article and activatingthe activatable material so that it expands and bonds to a surface ofthe article. The structural reinforcement may also be employed to sealand/or baffle the cavity. In a preferred application, the structuralreinforcement is employed to reinforce a transportation vehicle, such asan automotive vehicle.

By way of example, the structural reinforcement may be positioned withina cavity of a transportation vehicle (e.g., an automotive vehicle) priorto coating the vehicle. The activatable material may be activated whensubjected to heat during paint shop baking operations. In applicationswhere the activatable material is a heat activated, thermally expandingmaterial, an important consideration involved with the selection andformulation of the material comprising the activatable material is thetemperature at which a material reaction or expansion, and possiblycuring, will take place. For instance, in most applications, it isundesirable for the material to be reactive at room temperature orotherwise at the ambient temperature in a production line environment.More typically, the activatable material becomes reactive at higherprocessing temperatures, such as those encountered in an automobileassembly plant, when the material is processed along with the automobilecomponents at elevated temperatures or at higher applied energy levels,e.g., during paint or e-coat curing or baking steps. While temperaturesencountered in an automobile assembly operation may be in the range ofabout 140° C. to about 220° C., (e.g., about 148.89° C. to about 204.44°C. (about 300° F. to 400° F.)), body and paint shop applications arecommonly about 93.33° C. (about 200° F.) or slightly higher. Followingactivation of the activatable material, the material will typicallycure. Thus, it may be possible that the activatable material may beheated, it may then expand, and may thereafter cure to form a resultingfoamed material.

As indicated, the teachings herein also relate to a method for making acarrier for an activatable material (e.g., for structural reinforcementfor an article). The method may include a step of inserting at least onefibrous insert (which may be consolidated at the time of the step ofinserting) having an outer surface and including at least one elongatedfiber arrangement into a cavity of a tool. A mass of polymeric materialmay be molded in contact with the fibrous insert so that a resultingmolded mass of polymeric material integrally adjoins the fibrous insert(which is consolidated in its final state) and the outer surface of thefibrous insert is at least partially co-extensive and continuous withthe outer surface of the resulting molded mass of polymeric material. Amass of activatable material may be applied (e.g., overmolded,mechanically attached or otherwise) selectively over at least a portionof one or both of the outer surface of the resulting mass of thepolymeric material or the fibrous insert. Consistent with the teachingsabove, the mass of activatable material may be capable of activation forexpansion by an external stimulus (e.g., to at least partially, if notcompletely, fill a gap or a cavity) and may be capable of curing to forman adhesive bond to at least one surface of the article to which it isattached.

The method may include a step of at least partially shaping the fibrousinsert after it is placed in the cavity of the tool. For example, thetool may be preheated to a temperature above the softening temperatureand/or the melting temperature of a polymer of the at least one fibrousinsert prior to placing the fibrous insert in the cavity of the tool.The method may include a step of at least partially shaping the fibrousinsert after it is placed in the cavity of the tool and while moldingthe mass of polymeric material. For instance, heat and/or pressure thatresults from introducing the mass of polymeric material into the cavity(e.g., by injection molding), may at least partially cause the fibrousinsert to assume a shape dictated by one or more of the walls definingthe cavity. Thus it is possible that the fibrous insert is not preformedprior to placement in the cavity, and it assumes its final shape onlywhile in the cavity. Of course, it is also possible that the fibrousinsert is preformed prior to placement in the cavity.

The fibrous insert, prior to the inserting step, may be provided in theform of one or more layers of a tape and/or sheet, in which the fibersmay be fixed in position relative to each other (e.g., as a result ofconsolidation, by which a cohesive mass of the fibers distributed in acontinuous polymeric matrix is formed). The method may thus include astep of fabricating the fibrous insert to include a plurality of layersof tape and/or sheet. For example, the method includes a step ofconsolidating a plurality of layers of tape and/or sheet while theplurality of layers is subjected to heat and optionally an elevatedpressure. For instance, a temperature may be employed that is above themelting and/or softening point of the polymer of the tape and/or sheetto cause two or more adjoining layers to fuse and remain joined togetherupon cooling. A pressure of about 0.1 to about 1 MPa may be applied(e.g., about 0.2 to about 0.6 MPa). The temperature and pressure may beemployed for a desired amount of time to achieve essentially completedensification. It will be appreciated that the teachings afford for theformation of various consolidated insert structures.

The fibrous insert may be thermoformed to form a predetermined shape.The fibrous insert may be thermoformed during a step of consolidating. Aresulting thermoformed fibrous insert may thereafter be placed in a toolcavity and molten thermoset polymeric material may be introduced incontact with it.

The step of molding may include a step of introducing molten polymericmaterial into the tool cavity by way of a gate that is positioned ingenerally opposing relationship with the at least one fibrous insert. Inthis manner, upon introduction into the cavity, the molten polymercontacts the fibrous insert before it contacts a wall defining thecavity.

Carriers made in accordance with the present teachings may have a wallhaving a first surface and a generally opposing second surface. The wallmay have a thickness ranging from about 0.2 to about 6 mm (e.g., about1.5 to about 4 mm). At select regions within a carrier, it is possiblethat at least about 20%, 40%, 60%, 80% or even 100% of the wallthickness is defined by the fibrous insert or overlay. The fibrousinsert or overlay may have a contoured outer surface portion that isvisibly exposed on the carrier. The fibrous insert or overlay may have agenerally flat outer surface portion that is visibly exposed on thecarrier. The first surface and the second surface may be generallyparallel to each other.

The fibrous insert or overlay may occupy at least about 10%, 20%, 30% oreven 40% by weight of the overall carrier. The fibrous insert or overlaymay be less than about 90%, 80%, or even 70% by weight of the overallcarrier.

Thus it is possible that at least a portion of the first surface and thesecond surface are each visibly exposed and will be composed of thefibrous insert or overlay. The carriers may have one or more additionalstructural reinforcements or other structural features, such as one ormore ribs, bosses or otherwise. These features may be free of or theymay include a fibrous insert in accordance with the present teachings.

It is contemplated that the materials as disclosed herein may bepaintable. Paintability may be desirable, for example, if any surface isvisibly exposed. The material may be ink jet printed. The material maybe painted with conventional e-coat systems. The material may bepaintable, as it may have an affinity for taking paint. This may be due,at least in part, to the polarity of the material and/or the hydroxylfunctionality of the backbone (e.g., generally linear backbone polymerchain).

Parts herein may be employed for any of a number of purposes. Forexample, they may be employed to structurally reinforce a transportationvehicle such as an automotive vehicle. In this regard, a part may beplaced in a cavity of a vehicle body structure, such as a vehicle frame.After applying an e-coat layer to the vehicle body (e.g., within thecavity), the part may be subjected to heat from a bake oven, whichcauses the activatable material to activate (e.g., expand and fill thecavity), and become bonded to the vehicle body. A method for making anarticle in accordance with the present teachings may be performed in acontinuous manner. For example, fibrous material from a continuoussupply (e.g., a reel of the desired fibrous material (e.g., in itsdesired form, such as a strand, a yarn, a weave, nonwoven mat, orotherwise as described herein) for use as the distributed phase) may befed continuously to and through a die. The fibrous material may becontacted (e.g., by way of a suitable coating operation, such as rollcoating, or otherwise) with the thermoset polymer reaction product priorto or at the time when the fibrous material is passed through the die.The fibrous material may be contacted (e.g., by way of a suitablecoating operation, such as roll coating, or otherwise) with thereactants for the thermoset polymer reaction product prior to or at thetime when the fibrous material is passed through the die. Upon exitingthe die, a composite mass results. The fibrous material may thus form adistributed phase within the composite mass. The mass may be cut, shapedor otherwise subjected to another (e.g., a secondary) operation torender a composite article suitable for use for an intended application.

It may be possible also that a step of co-extrusion may be employed. Thestep of co-extrusion may include a step of passing a composite mass,such as described above, through a die, while also feeding a supply ofbase material through the die. The base material may be a polymericmaterial, a metal material or otherwise. Conditions may be maintainedwhile the materials are passed through the die so that the compositemass becomes bonded to (e.g., mechanically, adhesively, covalently, orany combination thereof), to the resulting shaped base material. Forexample, it may be possible that the heat from the base material whileit is processed through the die, or essentially immediately thereafter,may be sufficiently hot to cause the thermoset polymer reaction productto fuse with or otherwise bond to the base material.

As can be appreciated, a variety of suitable composite profiles arepossible as a result of the teachings. The profiles may include alongitudinal axis. The composite profiles may be symmetric or asymmetricrelative to the longitudinal axis. The composite profiles may includeone or more longitudinally oriented ribs. The composite profiles mayinclude one or more transversely extending flanges. The compositeprofiles may have one or more outer surfaces. The composite profile mayhave one or more inner surfaces. The composite profiles may include acomposite overlay that includes or consists of a composite mass of thepresent teachings. The composite profiles of the teachings may include acomposite overlay that includes or consists of a composite mass of thepresent teachings. The composite overlay may cover all or part of anouter or inner surface. The composite overlay may include or consist ofa composite mass of the present teachings may define all or part of arib, a flange (e.g., a transversely oriented flange) or both. Thecomposite profiles may include a composite mass that is at leastpartially or even completely embedded within the base material over someor all of the length of the composite profile. The composite profile mayinclude an extruded profile structure defining a mechanical attachmentfor securing the profile to another structure (e.g., such as isdisclosed in U.S. Pat. No. 7,784,186 (incorporated by reference; see,e.g., FIGS. 4-8 and associated written description). The compositeprofile may also have one or more push pin type fasteners such asdisclosed in U.S. Pat. No. 7,784,186 (incorporated by reference; see,e.g., FIGS. 1-3 and associated written description). Any of the abovecan be employed for use as an extruded carrier for a structuralreinforcement and/or baffle (e.g., for a transportation vehicle).

For use as an extruded carrier for a structural reinforcement and/orbaffle (e.g., for a transportation vehicle), there may also be employedan activatable material or at least a portion of an outer surface of thecarrier.

The composite material of the present teachings offers the benefit ofmechanical properties typically achieved through the use of thermosetpolymeric materials as some or all of a matrix phase of a composite.However, the material has a number of physical attributes that make itsuitable for handling and processing, as can be appreciated form theabove discussion of processing. The material of the present teachingscan also provide post-useful life reclamation, recycling, and/or re-usebenefits. The present teachings thus also contemplate methods thatinclude one or more steps of post-useful life reclaiming, recycling,and/or re-using the materials of the present teachings. For example, astep may be employed of separating the polymeric phase (e.g., thepolymeric matrix phase) from the distributed phase. A step may beemployed of re-using one or more phases of the composite of the presentteachings. A step may be employed of recycling one or more phases of thepresent teachings (e.g., processing at least one of the phases to adifferent form, size and or shape, from its original form, size and/orshape in the composite material of the present teachings. The materialof the present teachings may exhibit a high elongation factor so that itis not brittle yet still very strong. The material may be able to bondto a desired part, substrate, or location. This provides a benefit thatassembly operations may be free of welding. The assembly operation maybe free of an assembly tolerance stackup. As components may be bondedtogether (e.g., without mechanical fasteners), the parts may be free ofholes, thereby improving precision and eliminating inconsistent punchingoperations (e.g., with sheet metal). The material may ease geometricdimensioning and tolerances.

The polymeric material for the matrix of the fibrous composite materialof the teachings may be the same as or different from a polymeric bodyof the carrier, in instances in which the fibrous composite material ofthe teachings is employed on or within a polymeric body of the carrier.

FIGS. 1-11 illustrate examples in accordance with the present teachings.With reference to FIG. 1, there is seen a carrier 10 that has one ormore masses 12 of a first polymeric material. A fibrous insert 14 isshown joined to the one or more masses along an edge of the insert. Aninterface portion 16 is depicted (in exaggerated form for purposes ofillustration; for simplicity such interface is omitted from theremaining drawings, though it should be appreciated that it may stillexist in such embodiments). The carrier has an upper surface 18 and alower surface 20. The fibrous insert 14 spans from the upper surface tothe lower surface so that the fibrous insert is exposed visibly top andbottom. FIG. 1 omits any activatable material. However, activatablematerial can be located over either or both of the mass 12 or thefibrous insert 14.

FIG. 2 depicts a carrier 110 having a mass of polymeric material 112 anda fibrous insert 114, in which only the upper surface of the fibrousinsert is exposed. A lower surface and side edges adjoin the mass ofpolymeric material. The interface region is omitted in this depiction,though it may be present. In this drawing, an expandable material 126 islocated over both the mass of the polymeric material and the fibrousinsert. However, it can be located over one or the other as well.

FIG. 3 illustrates an example of a carrier 210 having a fibrousreinforcement portion 214 with an upper surface 218, from which a rib222 projects, which is made of a mass of polymeric material (e.g., thesame type of material as is otherwise present in the carrier to whichthe insert adjoins). The rib includes an outwardly projecting portionhaving a width w₁, and an enlarged neck region that has a width (at itslargest dimension) w₂ that is larger than the width w₁, such as by anamount of at least about 10%, 20% or 30%. The width w₂ may be largerthan the width w₁, such as by an amount of no greater than about 100%,80% or 60%. A similar rib structure can be employed in the embodiment ofFIG. 2.

FIGS. 4a and 4b illustrate two views of an illustrative carrier 310 thatincludes a mass of polymeric material 312 and a pair of fibrous inserts314. In this instance the fibrous inserts have upper and lower surfacesthat are exposed. Though it is possible to employ a structure like inFIG. 2, in which only an upper surface is exposed. A plurality of ribs322 are employed (ribs are shown in transverse disposition relative to alongitudinal axis (however for all of the embodiments herein, ribs mayrun longitudinally, transverse, diagonally, or any combination thereof;ribs may also be arcuate)). An activatable material 326 is shown. Thoughshown in a groove, it may rest on an outer surface or otherwise becarried on the carrier for all of the embodiments herein.

FIG. 5 illustrates an example of how fibrous inserts 14, 114, 214 or 314can have multiple layers with two or more adjoining layers havingdifferent fiber orientations. Though shown as unidirectionally orientedin this example, strips of impregnated fibers may also be provided as awoven layer. Other orientations than those disclosed in FIG. 5 arepossible. For example three layers of uniaxially oriented fibers may beoriented at 0/90/0 degrees relative to each other, or five layers may beoriented at 0/45/90/45/0 degrees relative to each other. Otherorientations are also possible.

FIGS. 6a and 6b illustrate an example of one part in accordance with thepresent teachings. The part includes a carrier 610 that is shown as amolded part. It includes a fibrous insert 614. The carrier includes aplurality of ribs 622. Activatable material 626 is applied over aportion of the carrier, and is shown as partially covering the insert614. The insert 614, which is overmolded for defining the carrier 610,includes an arcuate surface, and specifically a concave surface portion640. In the embodiment shown, it is located toward an end of the insert614. The insert 614 also includes a through-hole aperture 642. Theinsert includes a pair of opposing walls 644 (which may be generallyparallel or otherwise oriented) and a cross wall 646. The insert spans acentral portion of the carrier.

FIGS. 7a and 7b illustrate an example of another part in accordance withthe present teachings. The part includes a carrier 710 that is shown asa molded part. It includes a fibrous insert 714. The carrier includes aplurality of ribs 722. Activatable material 726 is applied over aportion of the carrier, and is shown as partially covering the insert714. The insert 714, which is overmolded for defining the carrier 710,includes an arcuate surface portion 740. In the embodiment shown, it islocated toward an end of the insert 714. The insert 714 also includes athrough-hole aperture 742. The insert includes a pair of opposing walls744 (which may be generally parallel or otherwise oriented) and a crosswall 746. At least one step 748 is defined in the insert.

FIG. 8 illustrates schematically how a carrier may be made in accordancewith the present teachings. A reel of fibrous material 850 may supplythe material to define an insert 814, shown as being sinousoidal. Theinsert may be overmolded to define overmolded portions 852 (e.g.,including a plurality of ribs) of a resulting carrier 810. The resultingcarrier, thus includes the insert 814 and the overmolded portions 852.

FIG. 9 illustrates an example of an extruded profile in accordance withthe teachings for use as a carrier 910. The profile includes a shaped(e.g., by rolling or otherwise being extruded) fibrous compositematerial overlay 960 over an outer surface of carrier shaped body 962(e.g., an extruded polyamide or glass filled polyamide, such as Nylon®).The carrier shaped body 962 has an inner surface 964. A rib 966 extendsaway (e.g., generally orthogonally) from the inner surface 964. Anactivatable material A is shown. The activatable material A may havebeen extruded onto the carrier.

FIG. 10 illustrates an example of a possible manufacturing system 1070that may be employed for an extrusion operation in accordance with thepresent teachings. Raw material for forming a base polymeric materialbody are fed into a hopper 1072 associated with an extruder 1074. Theextruder 1074 has a die 1076 through which the raw material is passed toform a shaped body profile 1078 (e.g., an extruded profile). The shapedbody profile may be cooled (e.g., by a vacuum cooler 1080) to a desiredtemperature. A feed system 1082 may feed a fibrous material 1084 (e.g.,by way of rollers) to a roll coater 1086 at which the material forforming a polymeric matrix is contacted with the fibrous material. Aforming roller 1088 (or another suitable extrusion type shaping device)may then further define the desired shape of the resulting fibrouscomposite material. The forming roller may also serve to help join thefibrous composite material with the shaped base body profile. Uponjoinder the resulting overall composite 1090 may be cooled (e.g., by acooling tank 1092). Optionally, if to be employed for use as a carrierfor a baffling and/or structural reinforcement application, theresulting overall composite 1090 may be advanced by a conveyor device(e.g., a pulling or pushing device) 1094. An activatable material may beapplied to the composite 1090 by an extruder 1096 (e.g., a cross headextruder). Thereafter, the resulting composite (with or without theactivatable material on it) may be cut by a suitable cutting device 1098(e.g., a traveling cut-off saw). By way of illustration, withoutlimitation, the raw material may be a glass filled Nylon® heated toabout 260° C. Upon exiting the cooler, the temperature may be about 150to about 175° C. Upon exiting the cooling tank the composite may be at atemperature of about 120° C. At the time of passing the extruder, thetemperature may be about 90-95° C. The cross-head extruder may extrudeone or more masses of a heat activatable epoxy-based structural foam,such as a structural reinforcement material in the L-55xx series,available from L&L Products, Inc. The manufacturing system may alsoinclude one or more pultrusion steps.

As shown for example at FIGS. 11A-11C, the profile 1110 may be formed asa continuous fiber pultruded carrier 1112 including a thermosetmaterial. In fact the carrier 1112 may comprise solely the thermosetmaterial and may be free of any additional polymeric materials.Alternatively, only a portion of the carrier 1112 may be formed of thethermoset material. The carrier may further include a sealant material1114 which may be added to the carrier, during or after the pultrusionprocess. The carrier may also include the addition of one or more filmportions 1116. The film portions 1116 may improve bonding betweendissimilar materials and/or assist in corrosion prevention, such thatthey may be located about and/or adjacent to one or more openings forreceiving a fastener. The carrier and one or more of the attachedmaterials referenced above may also be extruded.

It will be appreciated that, even though the embodiments of FIGS. 1through 11 are shown separately, features of one may be combined withfeatures of another and remain within the present teachings. Thedepictions therein thus should be regarded as generalized and applicableto the teachings as a whole herein.

The teachings herein are illustrated in connection with a carrier for astructural reinforcement, in which the carrier is generally elongated(e.g., it may be at least about 25 mm long, at least about 50 mm long oreven at least about 100 mm long). However, the teachings are notintended to be so limiting. The teachings also contemplate their usagefor forming carriers for baffling and/or sealing. The carriers may thushave lengths that are shorter than about 25 mm (e.g. about 15 mm orshorter). The carriers may be longer than they are wide. The carriersmay be wider than they are long.

As can be appreciated from the teachings herein, various benefits and/oradvantages may be realized. For example, parts may be prepared that havea carrier that is made of a material free of a thermosetting plastic.Parts may be prepared that have at least a portion of the activatablematerial located over and in contact with a fibrous insert of thepresent teachings.

As used herein, unless otherwise stated, the teachings envision that anymember of a genus (list) may be excluded from the genus; and/or anymember of a Markush grouping may be excluded from the grouping.

Unless otherwise stated, any numerical values recited herein include allvalues from the lower value to the upper value in increments of one unitprovided that there is a separation of at least 2 units between anylower value and any higher value. As an example, if it is stated thatthe amount of a component, a property, or a value of a process variablesuch as, for example, temperature, pressure, time and the like is, forexample, from 1 to 90, preferably from 20 to 80, more preferably from 30to 70, it is intended that intermediate range values such as (forexample, 15 to 85, 22 to 68, 43 to 51, 30 to 32 etc.) are within theteachings of this specification. Likewise, individual intermediatevalues are also within the present teachings. For values which are lessthan one, one unit is considered to be 0.0001, 0.001, 0.01, or 0.1 asappropriate. These are only examples of what is specifically intendedand all possible combinations of numerical values between the lowestvalue and the highest value enumerated are to be considered to beexpressly stated in this application in a similar manner. As can beseen, the teaching of amounts expressed as “parts by weight” herein alsocontemplates the same ranges expressed in terms of percent by weight.Thus, an expression in the of a range in terms of “at least ‘x’ parts byweight of the resulting composition” also contemplates a teaching ofranges of same recited amount of “x” in percent by weight of theresulting composition.”

Unless otherwise stated, all ranges include both endpoints and allnumbers between the endpoints. The use of “about” or “approximately” inconnection with a range applies to both ends of the range. Thus, “about20 to 30” is intended to cover “about 20 to about 30”, inclusive of atleast the specified endpoints.

The disclosures of all articles and references, including patentapplications and publications, are incorporated by reference for ailpurposes. The term “consisting essentially of” to describe a combinationshall include the elements, ingredients, components or steps identified,and such other elements ingredients, components or steps that do notmaterially affect the basic and novel characteristics of thecombination. The use of the terms “comprising” or “including” todescribe combinations of elements, ingredients, components or stepsherein also contemplates embodiments that consist of, or consistessentially of the elements, ingredients, components or steps.

Plural elements, ingredients, components or steps can be provided by asingle integrated element, ingredient, component or step. Alternatively,a single integrated element, ingredient, component or step might bedivided into separate plural elements, ingredients, components or steps.The disclosure of “a” or “one” to describe an element, ingredient,component or step is not intended to foreclose additional elements,ingredients, components or steps.

It is understood that the above description is intended to beillustrative and not restrictive. Many embodiments as well as manyapplications besides the examples provided will be apparent to those ofskill in the art upon reading the above description. The scope of theinvention should, therefore, be determined not with reference to theabove description, but should instead be determined with reference tothe appended claims, along with the full scope of equivalents to whichsuch claims are entitled. The disclosures of all articles andreferences, including patent applications and publications, areincorporated by reference for all purposes. The omission in thefollowing claims of any aspect of subject matter that is disclosedherein is not a disclaimer of such subject matter, nor should it beregarded that the inventors did not consider such subject matter to bepart of the disclosed inventive subject matter.

What is claimed is:
 1. A device comprising: (a) an elongated pultrudedcarrier, the carrier including: i) a fiber phase and a polyurethanematrix phase, the fiber phase being surrounded in its entirety by thematrix phase; and ii) a longitudinal axis whereby the carrier is shapedsymmetrically on opposing sides of the longitudinal axis; (b) anexpandable sealant material located in direct planar contact with aportion of the carrier, the expandable sealant material being locatedonto the carrier in a continuous manner via a pultrusion or extrusionprocess; and (c) one or more film layer portions located in directplanar contact with the carrier, the one or more film layer portionsbeing located onto the carrier in a continuous manner via a pultrusionor extrusion process, wherein the one or more film layer portions aredisposed on the carrier about one or more fastener openings of thecarrier and the one or more film layer portions are substantially freeof contact with the expandable sealant material prior to any activationof the expandable sealant material; wherein the carrier is formed toinclude a rib structure extending along the longitudinal axis of thecarrier, and the rib structure is free of contact with the expandablesealant material and the one or more film layer portions; wherein thecarrier includes an outer surface and an opposing inner surface, and therib structure projects from the inner surface; and wherein theexpandable sealant material is located on both the outer surface and theopposing inner surface of the carrier.
 2. The device of claim 1, whereinthe one or more film layer portions comprise a polyethylene material. 3.The device of claim 1, wherein the device is formed of at least fourdistinct material layers.
 4. The device of claim 3, wherein the at leastfour distinct material layers include a fiber layer, a matrix layer, afilm layer and an expandable material layer.
 5. The device of claim 4,wherein the fiber layer comprises glass fibers, the film layer comprisespolyethylene, and the expandable material layer comprises an epoxymaterial.
 6. The device of claim 1, wherein the device is cut intomultiple pieces after formation.
 7. The device of claim 1, wherein thefiber phase comprises glass fibers arranged generally parallel to eachother and having an average diameter of about 5 to about 25 microns,wherein each fiber has a length of at least 5 cm.
 8. The device of claim1, wherein the device has a substantially constant profile along thelongitudinal axis.
 9. The device of claim 1, wherein the carrier isformed to include at least two rib structures, and the at least two ribstructures are free of contact with both the expandable sealant materialand the one or more film layer portions.
 10. The device of claim 9,wherein the at least two rib structures are off-centered from thelongitudinal axis and extend substantially parallel to the longitudinalaxis.
 11. The device of claim 1, wherein the fiber phase comprises glassfibers.
 12. The device of claim 11, wherein the one or more film layerportions comprise a polyethylene material.
 13. The device of claim 11,wherein the device is formed of at least four distinct material layers.14. The device of claim 13, wherein the at least four distinct materiallayers include a fiber layer, a matrix layer, a film layer and anexpandable material layer.
 15. The device of claim 14, wherein thedevice is cut into multiple pieces after formation.
 16. The device ofclaim 14, wherein the device has a substantially constant profile alongthe longitudinal axis.
 17. The device of claim 11, wherein the devicehas a substantially constant profile along the longitudinal axis.